Today in about 4 hours I was able to get the aftermarket connectors crimped and soldered onto the new regulator/rectifier. This was the easy part, if I messed up I'd only kill the new regulator/rectifier and not have to replace the bike's wiring harness.
The first step was labeling the white wires. Hypothetically they can go in any order but I'm paranoid.
Step 2, removing the OEM connector.
Next step is to slide on the new connectors, then crimp and solder them into position. This went fine, except the red and black wires seem to be a thicker gauge than the white wires. So there was more wire than what would slide into the PowerPole connector. I did what I could, which was to jam as much wire into the connector as possible, then solder the excess wire to the outside of the connector and file down the excess. Not ideal to be sure.
After the connectors are soldered on the plastic housing slides over until it clicks into place. The technique is to hold the bottom end of the connector with needle-nose pliers and slide the housing over the connector until it clicks.
After all the connectors are on, the new regulator is mounted on the bike and the cable is routed into position.
White marks on the connectors are to note white wires. That was another 4 hours' work, and the end of the 2nd day of the project.
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